System and method for extracting articles from a slot

ABSTRACT

The present invention relates to a system and method for laterally extracting articles from a slot. The slot may belong to a DPP machine and housed within a DPP container. The present invention includes an extraction device with moveable walls that may be compressed and uncompressed a selectively width so as to define a cavity of the select width. The extraction device is inserted into the slot. The separator sheets are removed. The extraction device walls are compressed so as to make room between them and the slot walls. The separator sheets are reintroduced into this room. The extraction device is then pushed forward, out of the slot, and into a further processing element where the articles are deposited. The slot is then returned to a start position behind the slot. The extraction device includes an H-belt to facilitate removal of the articles from the extraction device cavity.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority to provisional patent application 60/499,612, filed on Sep. 3, 2003, which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

The present invention is directed to the field of article handling and more particularly to a system and method for extracting articles from a slot. Articles as used throughout the application is defined as at least one of mail, books, magazines and the like. The articles are typically sorted by a delivery point packaging machine (DPP). DPP machines are used to sort large batches of articles into appropriate slots. The articles are fed into the machine by feeders which also decode the article's destination address and thickness. The DPP includes a plurality of slots, stored in larger containers, for receiving articles logically assigned to destination addresses. Once an article's address is known (as will be the case when the article is fed into the DPP) the article is routed to its respective slot. The slots are stored in containers, themselves stored in a casing of a tower. The tower may also include article transport and delivery means by which the articles are physically transported to their respective slots. After a batch of articles has been sorted into their respective slots in accordance with a desired sequence (such as a delivery route sequence), it becomes necessary to physically remove or extract the articles from their slots and further process them. Such further processing may include polywrapping, manual handling and so forth. For such further processing and subsequent handling, it is a requirement of article extraction that the sequence and sorting order be preserved. The present invention is directed to this application. While discussed with respect to DPP machines, application of the present invention may be applied elsewhere as envisioned by the skilled artisan.

Current systems for extracting articles axe cumbersome, complicated, bully and present engineering challenges. Additionally, extracting systems have not been effectively applied to DPP and related sorting machines. Accordingly, a need exists in the art for effective and cost efficient article extraction.

SUMMARY OF THE INVENTION

The present invention is directed to a method for performing article extraction from a slot. The invention is further directed to a system for carrying out the above method. In the present method, an extraction device is inserted into a slot containing articles. The extraction device includes substantially parallel opposing side walls defining a cavity therebetween. The side walls are laterally displaceable, with respect to one another, thereby selectively widening and narrowing the cavity. By way of the insertion the articles are accommodated and held within the extraction device's walls. The separator sheets are then removed and reinserted outside the extraction device cavity. The extraction device is now free to relocate and remove the articles from the slot and deliver them to further processing. To facilitate extraction of the articles from the extraction device, the latter is equipped with an H-belt for providing a lateral force against the articles. After article extraction, the extraction device is brought back into its original stating position and the slot readied to receive new articles. The extraction device walls and separator walls include displaceable outer surfaces facilitating insertion and extraction within the slot without disturbing the articles.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

These and other embodiments of the present invention will be set out below in more detail with respect to the specification and claims, wherein like reference numerals refer to like parts. In the figures:

FIGS. 1 a-1 i depict various stages of operation of the present system; and

FIG. 2 depicts a flowchart method of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 a-1 i depict operating steps of the present system. FIG. 2 depicts a flowchart of the present method. Both system and method will be discussed with reference to all of the figures.

The slot 10 is depicted from above in FIGS. 1 a-1 i. As shown in FIG. 1 a, the slot includes an open back 12 and front 14 and a closed bottom 16. The slot includes substantially parallel opposing side walls 18 and 20 defining a cavity 22 therebetween. The side walls may include a friction free function which in operation does not resist insertion and removal items. The friction free function may be a product of side wall surface composition or other means known in the art.

Accommodated within cavity 22 are a plurality of articles 24 and two separator sheets 26 positioned between the articles 24 and side walls 18 and 20. The separator sheets 26 may comprise inward folded (towards one another) top and bottom ends 46 a and 46 b as well as an internal frame or member about which the separator outer covering or surface rotates and/or is otherwise displaceable (not shown). The internal frame may run the length of the separator sheet 26 or a portion thereof. The size and composition of the internal frame and outer covering is a matter of design choice. In operation, whenever the separator sheet 26 is insert or removed from a cramped or confined location, one being where another item is touching at least one of the separator outer covering surfaces, the outer covering may displace about the internal frame so as to prevent the transfer of force, due to friction, between the separator sheet and item. By way of outer covering movement the separator sheet may be removed from the cramped location and the items abutting the separator sheet remain in position undisturbed.

FIG. 1 a depicts an extraction device 30 behind slot 10 open back 12. The extraction device 30 may be displaceable towards and away from the slot as indicated by arrow 28. The extraction device 30 comprises two substantially parallel opposing walls 32 and 34 which define a cavity 42 therebetween. The walls 32 and 34 may comprise similar structure to the separator sheets 26. As such, the extraction device, via its walls 32 and 34, may be inserted into a cramped location, such as the slot cavity 22, without displacing items therein, such as articles 24. The extraction device further includes a cross web 36 connected to side walls 32 and 34. When the side walls 32 and 34 rotate about their internal frame, the cross web 36 is made to displace along the length of the side walls. The combination of the web 36 and side walls 32 and 34 in the shape of an H and will therefore be referred to as an H belt. The web 36 is selectively activated. The extraction device further includes side wall displacement means 38 arranged to move the side walls 32 and 34 closer together and further apart. The extraction device is depicted in its start location 40 with its side walls in a start position. The materials of the extraction device are a matter if design. The internal mechanics of the extraction device are also a matter of design choice provide the above functionality is maintained.

It is herein that the present method begins 50. Articles 24 have been sorted into slot 10 and two separator sheets 26 are included within the slot accommodating the articles therein (52, FIG. 2). The separator sheet are turned inward facilitating accommodation of the articles 24 within slot 10.

In FIG. 1 b, the extraction device 30 is inserted into slot 10 via the slot's open back 12. As a result of the insertion motion, side walls 32, 34 compressed the separator sheets 26 and articles 24 together (54, FIG. 2). Accommodated within extraction device cavity 42 are the articles 24 and separator sheets 26.

In FIG. 1 c, the back ends of the separator sheet 46 a are straightened rather than left internally inclined as depicted in FIGS. 1 a and 1 b. Forward ends 46 b remain inclined inward towards one another as was the position upon insertion (56, FIG. 2).

In FIG. 1 d, the separator sheets 26 are removed from the slot via the slot front 14 (58, FIG. 2). The separator sheet ends 46 a and 46 b now incline outward from one another. The articles 24 are now accommodated within cavity 42 of extraction device 30.

In FIG. 1 e, the extraction device side walls 32 and 34 are compressed inward via displacement means 38 so as to make room for the separator sheets 26 to be inserted between the side walls 32 and 34 and slot side walls 18 and 20 (60, FIG. 2). The separator sheet ends 46 a and 46 b are straightened and the separator sheets are reinserted between the respective side walls (62, FIG. 2).

In FIG. 1 f, the extraction device 30 is brought through the slot open front 14 and into another container 48 carrying the articles 24 within its' cavity 42 (64, FIG. 2). The separator sheets 26 remain in position within the slot 10. Container 48 represents further article processing which may include polywrapping, manual handling and the like as set out above. Lastly, the motion of the extraction device further straightens the separator sheet ends 46 b. The separator sheets or slot further comprise means for maintaining the separator ends straightened.

In FIG. 1 g, the extraction device 30 is reversed back into and through the slot 10 through open front 14 (66, FIG. 2). As a result of the rotation of the extraction device side walls 32 and 34, the web 36 moves forward with respect to the motion of the extraction device side walls 32 and 34 and/or remains in place with respect to the remaining elements of the figure. The web 36 assists in maintaining the articles 24 within cavity 42.

In FIG. 1 h, the extraction device is reversed through the slot, the separator sheet ends now being flat facilitate passage of the extraction device therethrough (68, FIG. 2). The reversing action brings the web 36 back to its start location. The extraction device side walls remain in a compressed position as was performed and depicted in FIG. 1 e. Alternatively, the web may remain in its forward position (not shown).

In FIG. 1 i, the back ends of the separator sheets 46 a are inclined inwards and the extraction device side walls 32 and 34 are expanded outward to their start position (70, FIG. 2). The extraction side walls are self adjusting or may be moved by other means known in the art. At this point, the slot is available for new articles and the method ends 72, FIG. 2.

The above mentioned actions are effected by means known in the art to provide the motions and responses depicted above. Specific devices to effect the above actions are a matter of design choice conforming to the described conditions.

The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications would be obvious to one skilled in the art are intended to be included within the scope of the following claims. Such modifications may include the number and location of extraction devices to slots. 

1. A method for laterally extracting at least one article from a slot, said slot comprising opposing walls defining a slot cavity for accommodating said at least one article, an open front and back, and at least one separator sheet accommodated within said cavity, comprising the steps of: inserting an extraction device into said slot so as to accommodate said at least one article within said extraction device, said extraction device comprising opposing walls defining a device cavity for accommodating said at least one article therein; removing said at least one separator sheet; compressing said extraction device opposing side walls; urging said extraction device through said open front; urging said at least one article from said extraction device; and returning said extraction device to a start position.
 2. The method according to claim 1, wherein said opposing side walls are laterally displaceable and said extraction device further comprises means for laterally displacing said side walls.
 3. The method according to claim 2, further comprising a web running between said opposing side walls and arranged so as to laterally displace in a direction of movement of said extraction device.
 4. The method according to claim 4, wherein said step of inserting said extraction device further comprises the step of laterally displacing said side walls.
 5. The method according to claim 1, wherein said at least one separator sheet comprises an internal member and a displaceable outer covering.
 6. The method according to claim 5, wherein step of removing said at least one separator sheet further comprises the step of displacing said outer covering.
 7. The method according to claim 3, wherein said step of urging said at least one article from said extraction device further comprises the steps of displacing said web in a direction of said urging such that said web contacts said at least one article and effects said urging.
 8. The method according to claim 1, further comprising the step of expanding said extraction device side walls after said step of returning said extraction device to a start position.
 9. The method according to claim 1, wherein said at least one article comprises at least one of mail, book, magazine, and compact disk.
 10. The method according to claim 1, further comprising the step of reintroducing said at least one separator sheet into said slot.
 11. The method according to claim 1, wherein said at least one separator sheet comprises two separator sheets.
 12. The method according to claim 11, further comprising the step of inserting said separator sheets between said extraction device side walls and said slot walls after said step of compressing said extraction device opposing side walls.
 13. The method according to claim 12, wherein each of said two separator sheets is inserted between a separate extraction device side wall and a proximate slot wall and remain in position during extraction device relocation.
 14. A system for laterally extracting at least one article from a slot, said slot comprising opposing walls defining a slot cavity for accommodating said at least one article, an open front and back, and at least one separator sheet accommodated within said cavity, comprising: means for inserting an extraction device into said slot so as to accommodate at least one article within said extraction device, said extraction device comprising opposing walls defining a device cavity for accommodating said at least one article therein; means for removing said at least one separator sheet; means for compressing said extraction device opposing side walls; means for urging said extraction device through said open front; means for urging said at least one article from said extraction device; and means for returning said extraction device to a start position.
 15. The system according to claim 14, wherein said opposing side walls are laterally displaceable and said extraction device further comprises means for laterally displacing said side walls.
 16. The system according to claim 15, further comprising a web selectively running between said opposing side walls and arranged so as to laterally displace with said side walls.
 17. The system according to claim 16, wherein said means for inserting said extraction device further comprises means for laterally displacing said side walls.
 18. The system according to claim 14, wherein said at least one separator sheet comprises an internal member and a displaceable outer covering.
 19. The system according to claim 18, wherein said means for removing said at least one separator sheet further comprises means for displacing said outer covering.
 20. The system according to claim 16, wherein said means for urging said at least one article from said extraction device further comprises means for moving said extraction device side walls so as to cause said web to laterally displace in a direction of urging thereby causing said at least one article to be urged in said direction.
 21. The system according to claim 14, wherein said at least one article comprises at least one of mail, book, magazine, and compact disk.
 22. The system according to claim 14, further comprising means for reintroducing said at least one separator sheet into said slot.
 23. The system according to claim 14, wherein said at least one separator sheet comprises two separator sheets. 